Load bearing tonneau structure

Abstract

A system and method for providing a folding load bearing hard tonneau cover which includes a hinge/connection element using a novel friction stir welding method to weatherproof the bed contents, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein the system does not rely on attached bed rails to support and lock the cover because loads are reacted on the bed caps, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the cover, wherein installation does not require modification to the bed, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, while still allowing a cover that folds open.

What is claimed is: 
     
       1. A tonneau cover, said tonneau cover comprised of:
 a plurality of tonneau sections, wherein each of the tonneau sections is constructed using friction stir welds, each of the tonneau sections including a hinge knuckle at each edge where it is joined to an adjacent tonneau section, each of the hinge knuckles being joined to respective tonneau sections using friction stir welding, and having a semi-circular element in the hinge knuckle; 
 a rubber hinge connection between each of the adjacent tonneau sections, wherein each of the rubber hinge connections is is disposed within the semi-circular element of two hinge knuckles; and 
 a rod that is inserted into circular elements of the rubber hinge connection so as to expand the rubber hinge connection and hold it securely within each semi-circular element in order to secure the rubber hinge connection between each of the adjacent tonneau sections. 
 
     
     
       2. The system as defined in  claim 1  wherein the rubber hinge includes a feature to prevent the hinge from being separated from the plurality of tonneau sections. 
     
     
       3. The system as defined in  claim 1  wherein the tonneau cover is further comprised of a plurality of D rings for providing points of attachment to a working surface of the tonneau cover, wherein the plurality of D rings are recessed beneath the working surface of the tonneau cover. 
     
     
       4. The system as defined in  claim 3  wherein the D ring is restrained by a flanged ring on an underside of the surface of the tonneau cover to thereby resist load. 
     
     
       5. The system as defined in  claim 1  wherein the tonneau cover is coupled to bed rails using a plurality of J clamps that eliminate a need for damaging the bed rails. 
     
     
       6. The system as defined in  claim 1  wherein the tonneau cover is further comprised of a spring loaded latch mechanism for releasing a first section of the plurality of tonneau sections from a tailgate so that the first section may be lifted and folded back onto a second section of the plurality of tonneau sections. 
     
     
       7. The system as defined in  claim 1  wherein the tonneau cover is further comprised of a storage compartment disposed on a bottom side of any section of the plurality of tonneau sections. 
     
     
       8. The system as defined in  claim 1  wherein the tonneau cover is further comprised of a plurality of attachment points disposed into the surface of the tonneau cover. 
     
     
       9. The system as defined in  claim 8  wherein the attachment points are threaded to enable a threaded screw to be coupled to the plurality of attachment points. 
     
     
       10. The system as defined in  claim 1  wherein the tonneau cover is further comprised of a moveable latch that couples the tonneau cover to any portion of a truck rail. 
     
     
       11. The system as defined in  claim 1  wherein the moveable latch is comprised of a magnetic system for magnetically holding the moveable latch in an open or a closed position. 
     
     
       12. A method for manufacturing a tonneau cover, said method comprised of:
 providing a plurality of tonneau sections, wherein each of the tonneau sections is constructed using friction stir welds, each of the tonneau sections including a hinge knuckle at each edge where it is joined to an adjacent tonneau section, each of the hinge knuckles being joined to respective tonneau sections using friction stir welding, and having a semi-circular element in the hinge knuckle; 
 providing a rubber hinge connection between each of the adjacent tonneau sections, wherein each of the rubber hinge connections is disposed within the semi-circular element of two hinge knuckles; and 
 inserting a rod into circular elements of the rubber hinge connection so as to expand the rubber hinge connection and hold it securely within each semi-circular element in order to secure the rubber hinge connection between each of the adjacent tonneau sections.